Insulated panel system

ABSTRACT

A building construction panel for use in wall, and roof construction is provided. The panel is connectable to a substantially similarly construction panel in first side to second side relation. The panel comprises: an exterior skin, an interior skin positioned opposite and parallel to the exterior surface; first and second side portions of the panel adjoining said exterior skin to said interior skin of the panel; said first side portion of said building construction panel spanning between said exterior and interior skin portions at a first edge of said building construction panel, and comprising a sidewardly extending first flange extending adjacent said interior skin; said second side portion of said building construction panel spanning between said opposed front and back portions at a second edge of said building construction panel opposite and parallel to said first edge, and comprising a groove in complemetary shape to said first flange. The first side portion includes a first protrusion member positioned at said exterior skin. The second side portion includes an exterior portion defining in part said groove and extending over said flange and including a lip member adapted to extend over said first protrusion member of an adjacent said panel in flush overlapping sealing relation therewith. The panel of the herein invention, provides improved resistance to water penetration at the sidelap of two adjacent panels.

FIELD OF THE INVENTION

This invention relates to interlocking panels for use in roof and vertical wall applications.

BACKGROUND OF THE INVENTION

Insulated metal panels are typically used on wall and roof building applications to form part or all of the building envelope. A panel typically has opposing inside and outside steel surfaces with an insulating foam core adhered between the surfaces. The panel can then be mounted onto support structures to form the wall or roof application in a building. The combination of steel and foam provides for a relatively lightweight insulating panel that can span significant distances between support structures.

One typical application is to use such panels to construct vertical walls. In these applications, continuous steel supports which form the shape of the walls typically run horizontally on the wall. The insulated metal panels are oriented such that the steel supports extend parallel to the width of the panels, as measured from side edge to side edge thereof. A first panel is fastened to the support. Additional panels are installed parallel to the first with one panel engaging the adjacent one with some form of sidelap or joint.

Another application is to use insulated metal panels to construct roofing structures. Similar to wall applications, the panels are screw fastened to the support structure on the roofing structure. Additional panels are installed parallel to the first with one panel engaging the adjacent one and joined at a sidelap.

One difficulty of roofing applications is that the exterior surface is exposed to significantly more water and other elements than for wall applications. While panels for wall applications are positioned vertically, panels for roofing applications are typically positioned at a non-vertical angle, often approaching a horizontal orientation. Thus, water and other elements drain more slowly. In such applications, there is the difficulty that water may penetrate at the joint where two panels meet. The water may also penetrate any fastening screws located at the sidelap.

One solution has been to the cover the screw at the sidelap with an additional cap to hide the screw and to provide water tightness. Another solution has been to use a concealed clip, often called a sliding clip or support clip, to engage the panels at the sidelap and then screwing the clip to the support structure. These methods may not provide the most effective resistance to water penetration and may involve additional components and/or field seaming to hide the attachment fasteners.

SUMMARY OF THE INVENTION

The present invention relates to an improved insulated metal panel for roofing and wall applications.

In accordance with an aspect of the invention there is provided a building construction panel for use in wall, and roof construction, and wherein said building construction panel is connectable to a next substantially similarly construction panel in first side to second side relation said building construction panel comprising: an exterior skin defining an exterior surface of the panel; an interior skin positioned opposite and parallel to the exterior surface and defining an interior surface of the panel; first and second side portions of the panel adjoining said exterior skin to said interior skin of the panel; said first side portion of said building construction panel spanning between said exterior and interior skin portions at a first edge of said building construction panel, and comprising an sidewardly extending first flange extending adjacent said interior skin; said second side portion of said building construction panel spanning between said opposed front and back portions at a second edge of said building construction panel opposite and parallel to said first edge, and comprising a groove in complemetary shape to said first flange, thereby adapted to accept said first flange of an adjacent panel in slide fit engagement; an insulative material disposed between said interior and exterior skins; said first side portion including a first protrusion member positioned at said exterior skin extending exteriorly from said first side portion, said first protrusion member oriented inwardly of said first flange; said second side portion including an exterior portion defining in part said groove and extending over said flange and including a lip member extending exteriorly from said second side portion, adapted to extend over said first protrusion member of an adjacent said panel in flush overlapping sealing relation therewith.

Other objects, features and advantages of the present invention will be apparent from the following non-restrictive description of example embodiments of the invention, made with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIGS. 1A and 1B are section views of first embodiments of panels in accordance with aspects of the invention;

FIG. 2 shows a cross-sectional elevation of the sidelap of adjacent panels in accordance with the first embodiment of the present invention;

DETAILED DESCRIPTION OF AN EXAMPLE EMBODIMENT OF THE INVENTION

As can be seen in FIGS. 1A, 1B and 2, example embodiments of panels of the herein invention are illustrated. Panels in accordance with the invention each have an exterior steel skin 14, an interior steel skin 16, and an insulating foam core 18 disposed between the exterior skin 14 and interior steel skin 16. The panels further include a first side edge portion 100 and an opposite second side edge portion 102 extending between the parallel interior skin 14 and exterior skin 16 surrounding the foam core 18.

Reference is made to FIG. 2, which shows a cross-sectional view of a sidelap between a the first side edge portion 100 of first panel 10 and the second side edge portion 102 of second panel 11. Such embodiments of panels are adapted particularly for roofing applications, however, such could be utilized in other applications, such as walls or flooring or the like.

As shown, the panels 10, 11 are mounted onto a support structure 12, as will be discussed further below. In wall applications, continuous steel supports typically run horizontally on the wall, often spaced vertically at 5 feet to 15 feet. In roofing applications, the support structure 12 may be comprised of regularly spaced beams extending perpendicular to the width of the panels 10, 11.

Example embodiments of the insulated metal panels in accordance with the invention have a thickness (measured from interior skin to exterior skin) ranging from 2 inches to 6 inches, length L (measured along side edges) of 1 to 60 feet (or as limited by handling limitations) and widths measured from first side edge to second side edge of 24 inches, 30 inches, 36 inches, and 42 inches. It should be understood that other dimensions may be provided as part of this invention and these preceding dimensions are listed as examples only.

As shown in FIGS. 1A, 1B and 2, in first embodiments of the invention, particularly designed for roofing applications, the first side end portion 100 includes a trapezoidal protrusion 20 extending exteriorly at the first side edge portion. At the second side portion, the exterior skin 14 has a sidewardly extending lip member 22 adapted to extend over the protrusion 20 of the first panel 10 when said first and second side edges are brought into slide fit engagement, discussed below. In the example embodiment shown the protrusion extends 35 mm (or approximately 1.5 inches) exteriorly from the exterior skin.

Adjacent to the interior skin 16 is a flange 26 extending sidewardly from the first side edge portion. The protrusion 20 is positioned inwardly of the flange 26 to ensure proper sealing of the joint is achieved and to allow the flange to be secured to the support structure. In the embodiments shown, the flange 26 is adapted to mate with a corresponding mating groove 27 in the second side edge portion 102 of an adjacent panel. Groove 27 is defined in part by exteriorly positioned groove wall 27 a of an exterior portion 29 of the second edge portion. The flange further includes a sidewardly extending tongue 32 which is adapted to mate with a corresponding groove 34 in the second edge portion 102 of second panel 11. Preferably the tongue 32 is positioned offset from the interior skin 16 such that the tongue may be enveloped on its interior and exterior side by the corresponding groove 34 of the second side portion 102. The second side edge portion 102 of second panel 11 may engage the first side edge portion 100 of first panel 10 by sliding the second panel 11 along the plane defined by support structure 12 such that the tongue 32 engages the groove 34 in a slide fit. The tongue 32 and groove 34 combination in part prevents the first panel 10 from disengaging the second panel 11 in a direction perpendicular to the surface of the support structure 12. In an example embodiment, a sealant 42 is applied between the tongue 32 and groove 34 to achieve additional water tightness. A sealant accepting region 43 may be defined between the tongue 32 and groove 34. The sealant 42 may be applied at the manufacturer site or on the building site. The tongue and groove are defined by the outer metal skin S which forms the exterior skin 14 and interior skin 16. In the embodiment shown, skin S defining groove 34 terminates with a skin lip 77 s.

In the embodiment of FIGS. 1 a, 1 b and 2, the protrusion 20 extends exteriorly from the exterior side of the first side portion 100 of the first panel 10. The lip 22 of the second panel 22 extends over the protrusion 20 for covering at least a portion of the protrusion 20. Preferably, the lip 22 is generally the same shape as the upper portion of the trapezoidal protrusion 20 and covers the top 20T and upper portion of side portions 20S of the trapezoidal protrusion. The lip covers the entirety of outer side portion 20SO. Since the engagement between the lip 22 and the protrusion 20 is elevated with respect to the exterior of the panels 10, 11, there is less penetration of water at the sidelap.

In the embodiment of FIGS. 1 a, 1 b and 2, the lip 22 has an end 24 defined therein which extends around the upper side edge portion of the protrusion 20S. The lip is positioned and shaped such that the end 24 does not obstruct the panels 10, 11, when the first side edge 100 of panel 10 is brought into slide fit engagement with second side edge 102 of panel 11. In fact, the lip 22 may be resiliently biased to snuggly fit over the protrusion 20, which allows the lip to deform exteriorly as the end 24 engages the top of the protrusion, and then return to position such that the lip snuggly engages the protrusion top and sides 20T and 20S, when the side edges portions 100 and 102 are engaged in slide fit together. A sealant 40 may be applied between the protrusion 20 and the lip 22 to achieve additional water tightness. In fact a water sealant accepting portion 41 may be formed in the protrusion where such sealant may be applied. The sealant 40 may applied at the manufacturer site or on the building site.

As shown in FIG. 2, as the second side edge portion 102 of second panel 11 engages the first side edge portion 100 of first panel 10 in the slide fit, the exterior wall 27 a of exterior portion 29 of the second side edge portion which defines groove 27 thereby covers the screw 28. Thus, additional caps are not necessarily required to hide the screw or to provide water tightness.

The exterior skin 14 and interior skin 16 may be flat or near flat. In embodiments shown in some of the figures, the exterior skin 14 and interior skin 16 may be fluted or corrugated. Such fluting or corrugation may take to form of small grooves detailed in the panels skin 10, 11 extending parallel to side edges 100, 102. Such corrugated skin provides additional structural support to each panel. The corrugations may be further spaced apart such as is shown in FIGS. 1 a and 1 b, and may be positioned on both the interior and exterior skins as in FIG. 1 a or just one of same, as in FIG. 1 b. Additional protrusions 20 may be positioned at regular spacing across the width of the panels for added support.

The skin 14, 16 may be formed of steel or galvanized steel with protective coatings such as zinc or aluminum and zinc. Paint may also be added for protection and appearance. The skin may also be formed of other suitable materials, such as for example stainless steel or aluminum or high density plastics.

The insulating foam core 18 may be any suitable rigid type insulation such as polyisocyanurate foam, polyurathane foam or such specific examples such as Owens Corning AF530/703, AF545/704, 705, Fibrex 1240, 1260, and/or Roxul RXL60, RXL80. The insulation should be of sufficient thickness to transfer gravity loads through the roof panel system to the support structure. In a particular embodiment, the panel has an R value of approximately 7.6 per inch.

A screw 28 secures the flange 26 of the first side edge portion to the support structure 12, at the fastening region 26F of the flange 26. A washer 28w is disposed between the head of the screw 28 and the flange 26. Although the screw 28 is shown in the present embodiment, it is envisaged that other fasteners or fastening means may be used for mounting the first panel 10 onto the support structure 12, for example a rivet, bolt, nail or the like.

After engagement of the second panel 11 with the first panel 10 in the slide fit as discussed above, the second panel 11 is then secured to the support structure at the first side edge portion thereof, by means flange 26 positioned at the first side edge portion of panel 11 in the manner discussed above.

In the embodiments discussed above tongues, such as tongue 32 extends from the first side edge portion with mating groove 34 positioned in the second side edge portion. It should be understood that the tongue 32 may be positioned on the second side edge portion with a mating groove on the first side edge portion

Although the invention has been described with reference to illustrative embodiments, it is to be understood that the invention is not limited to these precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art. All such changes and modifications are intended to be encompassed in the appended claims. 

1. A building construction panel for use in floor, wall, and roof construction, and wherein said building construction panel is connectable to a next substantially similarly construction panel in first side to second side relation, said building construction panel comprising: an exterior skin defining an exterior surface of the panel; an interior skin positioned opposite and parallel to the exterior surface and defining an interior surface of the panel; first and second side portions of the panel adjoining said exterior skin to said interior skin of the panel; said first side portion of said building construction panel spanning between said exterior and interior skin portions at a first edge of said building construction panel, and comprising an sidewardly extending first flange extending adjacent said interior skin; said second side portion of said building construction panel spanning between said opposed front and back portions at a second edge of said building construction panel, opposite and parallel to said first edge, and comprising a groove in complementary shape to said first flange, thereby adapted to accept said first flange of an adjacent panel in slide fit engagement; an insulative material disposed between said interior and exterior skins; said first side portion including a first protrusion member positioned at said exterior skin extending exteriorly from said first side portion, said first protrusion member oriented inwardly of said first flange; said second side portion including an exterior portion defining in part said groove and extending over said flange of an adjacent said panel and a lip member extending exteriorly from said second side portion, adapted to extend over said first protrusion member of the adjacent said panel in flush overlapping sealing relation therewith.
 2. A panel as recited in claim 1 wherein a sealant receiving region is defined between the lip member and the protrusion.
 3. A panel as recited in claim 2 wherein sealant is applied in the sealant receiving region.
 4. A panel as recited in claim 1 wherein said exterior skin of said building construction panel is corrugated; said corrugations running along the length of the panel, parallel to said side edges.
 5. A panel as recited in claim 1 wherein said flange may be fastened to a support member positioned beneath said interior skin by mechanical fastening means extending therethrough.
 6. A panel as recited in claim 5 wherein said flange includes a fastener receiving region for securing the flange to the support structure.
 7. A panel as recited in claim 6 wherein a fastener is located at the fastener receiving region for securing the flange to the support structure.
 8. The panel as recited in claim 1 wherein the flange further includes a sidewardly extending tongue which is adapted to mate with a corresponding groove in the second edge portion of second panel.
 9. The panel as recited in claim 1 wherein the second edge portion further includes a sidewardly extending tongue which is adapted to mate with a corresponding groove in the flange of the first edge portion of a second panel.
 10. A panel as recited in claim 1 wherein said lip member is resilient such that it deforms exteriorly as the protrusions slides into engagement therewith and returns to snuggly extend over said protrusion in sealing engagement therewith.
 11. A panel as recited in claim 1 wherein the protrusion is an exteriorly oriented trapezoidal shape including a top surface, an inner side edge and outer side edge.
 12. A panel as recited in claim 10 wherein said lip member comprises an end portion adapted to extend over an upper portion of the inner side edge, and further portions adapted to extend over the top surface and outer side edge of the protrusion.
 13. A panel as recited in claim 6 wherein said fastening receiving region is positioned interiorly of the exterior portion of the second side edge of an adjacent panel, such that it is covered when said adjacent panels are engaged with each other.
 14. A panel as recited in claim 1 wherein said skin comprises steel, galvanized steel, aluminum or stainless steel. 